Laminated gypsum partition

ABSTRACT

A laminated panel including at least two gypsum boards, laminated in offset relationship, with light gauge sheet metal wrapped around both side edges of each board, and wall structures thereof.

United States Patent [191 Schneller 1 Dec. 4, 1973 LAMINATED GYPSUM PARTITION [75] Inventor:

Joseph W. Schneller, Williamsville, NY.

[73] Assignee: National Gypsum Company,

[22] Filed:

Buffalo, NY.

June 19, 1969 21 App]. No.: 834,752

[52] U.S.Cl [51] Int.Cl.

E04b 2/08, E04c 2/ 14 [58] Field of Search 52/241, 242, 592,

References Cited UNITED STATES PATENTS Parslow... 52/601 Woodhouse.... 52/601 Baker 52/354 Mathews; 52/582 Primary Examiner-Henry C. Sutherland Attorney-Robert F. Hause [57] ABSTRACT A laminated panel including at least two gypsum boards, laminated in offset relationship, with light gauge sheet metal'wrapped around both side edges of each board, and wall structures thereof.

5 Claims, 6 Drawing Figures PATENTEDUEB 4191s 3.715.920

SHEET 1 0F 3 11V Vii/N TOR, Joseph W. Schneller ATTORNEY PATENIEDUEB m 3.715.920

SHEET 2 0F 3 INVEINTOR, Fig 6 Joseph W, Schneller ATTORNEY 1 LAMINATED GYPSUM PARTITION This invention relates to ceiling height panels of laminated gypsum boards having offset edges each edge being enwrapped with a sheet metal of a gauge suitable for attachment thereto of facing sheets with selftapping, self-threading wallboard screws.

Although the panels of the present invention provide definite advantages in many various applications, they have a particular advantage in providing a solution to the long standing problem of constructing a low-cost, fire retardant wall around shafts, such as the elevator shafts in high rise buildings. All work on elevator shaft walls must be carried on from just one side of the wall, unless expensive scaffolding is erected in the shaft.

Such walls have commonly been constructed of concrete block or brick, which construction is relatively expensive and time consuming. The cost of constructing walls is'based on material cost and labor cost, and the labor portion is continually becoming a larger proportion of the total cost. Accordingly, there is a continual search for wall systems providing the necessary physical characteristics and simultaneously providing for faster erection.

It is an object of the present invention to provide a novel wall structure for erection from only one side of the wall.

It is a further object to provide such a novel wall with physical characteristics sufficient for usearound shafts for high speed elevators.

These and other objects and advantages of the invention will be more readily apparent when considered in relation to the preferred embodiments as set forth in the, specification and shown in the drawings in which:

FIG. 1 is a perspective view of a 2 inch, metal edge, corewall embodying the present invention.

FIG. 2 is a perspective view of one of the 2 inch, metal edge, corewall panels of FIG. 1.

FIG. 3 is a perspective view of two linch' coreboards, with metal edges, with beads of adhesive in place, immediately prior. to lamination thereof into a corewall panel of FIG. 2.

FIG. 4 is a cross sectional view of a plurality of adjoining corewalls of FIG. 1.

FIG. 5 is a cross sectional view of a partition including the corewall of FIG. 1 and gypsum wallboard attached to one face thereof.

FIG. 6 is a cross sectional view of a partition including the corewall of FIG. 1 and gypsum wallboard attached to both faces thereof, at a juncture thereof with a door jamb.

Referring to FIG. 1 there is shown a floor l0 and a ceiling 12 adjacent an elevator shaft 14. At the edge 16 of floor 10 is a 2 inch X 2 inch, 16 gauge metal floor runner 18. At the edge of ceiling 12 is a 2 inch X 2 inch, 16 gauge metal ceiling runner 22. Floor runner 18 consists of a vertical flange 24 and a horizontal flange 26 and ceiling runner 22 consists of a vertical flange 28 a and a horizontal flange 30. The floor runner 18 and ceiling runner 22 are affixed respectively to the floor and ceiling by powderdriven fasteners 32 driven into the concrete, at two foot apart spacings.

2 inch thick, metal edge corewall panels 34, consisting essentially of two 1 inch thick, 16 inch wide metal edge coreboards 36 laminated together with a 2% inch lateral offset 38, are disposed on floor runner flange 26 and extend upward substantially to ceiling runner flange 30. The bottom edges of corewall panels 34 are affixed to floor runner flange 24 and the top edges to ceiling runner flange 28 by two self-drilling, selftapping drywall screws 40, of 2% inch length, one .at each edge. A 1 inch wide 24 gaugeflat metal strip 41 is disposed on the panel faces over the screw heads, affixed there by additional screws 40 at about 8 inch spacing. p

The metal edge coreboards 36 are each 1 inch thick paper-covered, gypsum boards, which may be manufactured onstandard gypsum wallboard machines in 48 inch widths and cut into 16 inch widths. Coreboards of 24 inch width are also suitable. Disposed over substantially the full length of each coreboard side edge is-a metal U-channel 42 of 24 gauge metal, including a 1 inch wide base 44 and two 1 inch wide side flanges 46.

In FIG. 3, there isshown two coreboards 36 with six A inch X 1 inch parallel beads 48 of adhesive disposed atop the lower of the two coreboards, at approximately 2 inch spacing starting from the left edge, and with the upper of the two coreboards disposed offset to, the left at least about 2 inches relative to the lowercoreboard,

but aligned with the lower coreboard at the ends, in position to be moved straight downward and adhered to the lower coreboard to form the corewall panels34.

To construct a corewall 50, consisting of panels 34, as shown in FIGS. 1 and 4, construction will typically start at an existing wall or column 52. A 2 inch X 2 inch, 20 gauge metal vertical runner 54 is affixed to column 52. Vertical runner 54 includes a base flange 56 and an outstanding flange 58, which is disposed in the same plane as floor and ceiling runner flanges 24 and 28.

One of the two 2% inch wide offsets 38 is removed to form a 2 inch flat edge 60 on thefirst panel 34 to be erected, and edge 60 is disposed in the vertical runner 54 and fastened to the outstanding flange 58 with 2% inch drywall screws 40, spaced 24 inches apart. The bottom and top edges are then also affixed to runners with screws 40. The first panel 34must be placed so that the remaining offset 38 is a part of the coreboard 36 which is farthest away from the side of the corewall 50 on which the construction men intend to stand while erecting the corewall, and, around an elevator shaft 14,

the offset 38 will be adjacent shaft 14.

The second and subsequent panels 34 are successively stood vertically in place and screw attached, disposing the bottom of the panel tight against floor runner flange 24, the upper edge against ceiling runner flange 28 and the offset 38 of the coreboard remote from the elevator shaft 14 is disposed on the side of the coreboard being erectedwhereby it will overlap the offset 38 ofthe previously erected panel 34.

The overlappedoffsets 38, 38 are then joined by 1% inch long self-drilling, self-tapping drywall screws 62 inserted through the offset 38 of the later erected panel 34, at two foot vertical spacings, so spaced from the edge that they extend through aside flange 46 of the channel 42 on theoffset 38 of the previously erected panel 34.

The corewall 50 could terminate at a second wall or column 52 by providing an appropriate width with a flat edge 60 on the last mounted panel 34, attached to a vertical runner 54. Alternatively, the corewall could be terminated at will by providing a last mounted panel 34 of an appropriate width with flat edge 60, and capping the flat edge with vertical 2 inch wide channel 64.

As seen in FIG. 4, abutting corewalls 50 can be screw attached at any place along an existing corewall, such as abutting wall 66 screw attached at the middle of an existing panel 34, abutting wall 68 at the side of the end of an existing corewall forming an inside comer 70 and abutting wall 72 with the side of its end abutting the end of an existing corewall, forming an outside corner 74.

In FIG. 5, there is seen a section of a corewall 50 having a face layer of gypsum wallboard 76 screw attached to the U-channels 42 of the corewall. A fire-rated partition is provided by applying wallboard 76 with long edges extending vertically, forming a joint 78 located over the U-channel 42 of an overlap 38 on the adjacent side of the corewall 50. Self-drilling, self-tapping 1 inch drywall screws 80 attach the wallboard edges to the adjacent U-channels 42 and attach the wallboard center portion to other adjacent U-channels 42. The joint 78 is covered and reinforced with standard joint tape 82 and joint cement 84.

When corewall 50 is used to provide the support and the base element of a partition between two rooms, wallboard 76 will be applied to both sides of corewall 50, with joints 78 concealed by tape 82 and cement 84, if desired. Doorways and window openings can be provided, and, for example, in FIG. 6 there is seen a section of a completed two room partition 86 having a central corewall 50 and wallboards 76 on both faces with the vertical edge 88 disposed within a typical extruded aluminum door frame 90. The corewall edge, at partition edge 88, is enclosed within a 2 inch channel 64 and the wallboards 76 may be affixed to channel 64 with drywall screws 80 if desired. A fixed head adjusting screw 92 forces a jamb anchor clip 94 firmly against channel 64 to fixedly position the door frame 90 in proper vertical alignment.

Having completed a detailed disclosure of the preferred embodiments of my invention so that those skilled in the art may practice the same, I contemplate that variations may be made without departing from the essence of the invention.

I claim:

1. A corewall comprising a plurality of corewall panels comprising two coreboards of a composition unsuitable for retention of screws, said coreboards being of substantially equal length and also of equal width and adhesively laminated together with the respective ends of said boards substantially aligned and the respective side edges of said boards offset at least about 2 inches forming offset portions of the portion of each said board which extends beyond the side edge of the other said board, elongate screwable metal channels disposed on each of the four coreboard side edges of said penel extending substantially the complete length of said side edges, said channels including an elongate base of a width equal to the coreboard thickness and two flanges extending perpendicular to said base and disposed on opposite face of said coreboards, each said panel being affixed at one end to a metal floor runner and at the other end to a metal ceiling runner, each pair of adjacent corewall panels having overlapping offset portions consisting of one offset portion of each of said panels of said pair, and a plurality of screws extending through at least one of said offset portions and into one of the flanges of the channel on the opposite offset portion.

2. A corewall as defined in claim 1 wherein said floor runner consists solely of a horizontal flange and an upwardly extending vertical flange and said ceiling runner consists solely of a horizontal flange and a downwardly extending vertical flange.

3. A corewall as defined in claim 2 wherein said panels are screw attached to said vertical flanges of said floor and ceiling runners.

4. A corewall as defined in claim 3 wherein a flat strip of metal is screw attached on the face of said panels adjacent the bottom and top edges thereof over the heads of said screws attaching said panels to said runners.

5. A corewall as defined in claim 1 wherein said screws are self-drilling, self-tapping drywall screws. 

1. A corewall comprising a plurality of corewall panels comprising two coreboards of a composition unsuitable for retention of screws, said coreboards being of substantially equal length and also of equal width and adhesively laminated together with the respective ends of said boards substantially aligned and the respective side edges of said boards offset at least about 2 inches forming offset portions of the portion of each said board which extends beyond the side edge of the other said board, elongate screwable metal channels disposed on each of the four coreboard side edges of said penel extending substantially the complete length of said side edges, said channels including an elongate base of a width equal to the coreboard thickness and two flanges extending perpendicular to said base and disposed on opposite face of said coreboards, each said panel being affixed at one end to a metal floor runner and at the other end to a metal ceiling runner, each pair of adjacent corewall panels having overlapping offset portions consisting of one offset portion of each of said panels of said pair, and a plurality of screws extending through at least one of said offset portions and into one of the flanges of the channel on the opposite offset portion.
 2. A corewall as defined in claim 1 wherein said floor runner consists solely of a horizontal flange and an upwardly extending vertical flange and said ceiling runner consists solely of a horizontal flange and a downwardly extending vertical flange.
 3. A corewall as defined in claim 2 wherein said panels are screw attached to said vertical flanges of said floor and ceiling runners.
 4. A corewall as defined in claim 3 wherein a flat strip of metal is screw attached on the face of said panels adjacent the bottom and top edges thereof Over the heads of said screws attaching said panels to said runners.
 5. A corewall as defined in claim 1 wherein said screws are self-drilling, self-tapping drywall screws. 